Injection molding factory system and manufacturing method

ABSTRACT

The present invention includes an injection molding factory system and an associated facility that comprises a building having a series of injection molding machines array on a first floor with the resin supply placed on a mezzanine level. The injection molding machines are arranged with automatic product conveyors to move injection molded product from the injection molding machines without the need for human operators or separate vehicles.

RELATED APPLICATION DATA

This application is a continuation of U.S. application Ser. No.13/405,635, filed Feb. 27, 2012, which is hereby incorporated herein inits entirety by reference.

FIELD OF THE INVENTION

The present invention relates to injection molding machines, theiroperation, and plant layouts therefor.

BACKGROUND OF THE INVENTION

Injection molding machines are expensive to purchase, require expensivefactory space and substantial quantities of electrical power.

The operation on an injection molding plant typically involves the useof an array of injection molding machines (often of varyingcapabilities) that are very expensive, precision equipment thattypically require technicians and/or operators directly involved intheir operation. Normally, operators will use hand trucks, forklifts andhoists to supply the machines with resin, to change mold sets and toremove molded product from the machines for further processing, testing,packaging and shipping.

Typical injection molding plant floor set-ups provide an array ofmachines that define required and relatively wide thoroughfares forpersons and heavy lifting and transport machinery. Injection moldingplants normally require a great detail of space to permit the storage,movement and injection of resin, as well as to permit the installationand replacement of mold sets, and the removal and packaging of thefinished product for shipment. The continuous movement of persons, heavymachinery and mold sets, resin bins and product containers aroundexpensive injection molding machines results in the constant risk toworkers and the machines themselves.

In addition, injection molding plants typically also require activelighting to facilitate the movement of operators, equipment, resin andfinished product.

Accordingly, it would be advantageous to have an injection moldingsystem and method of operation that is substantially more cost effectiveto manufacture and operate.

Additionally, it is desirable for such a system and method to be lessdependent upon operator input and to be capable of beingoperated/carried out in the absence of active lighting and/or that canbe remotely monitored based upon operational parameters.

SUMMARY OF THE INVENTION

The present invention includes an injection molding factory system andan associated facility that comprises a building having a series ofinjection molding machines array on a first floor with the resin supplyplaced on a mezzanine level. The injection molding machines are arrangedwith automatic product conveyors to move injection molded product fromthe injection molding machines without the need for human operators orseparate vehicles.

Injection Molding Machine Array with Narrow Inter-Machine Space

In a most fundamental aspect, the invention includes an array ofinjection molding machines having a product container conveyorassociated with each injection molding machine and disposed betweenadjacent injection molding machines such that the product containerconveyor is the sole means for accepting injection molded products fromits associated injection molding machine into product containers. In thepreferred embodiment, the invention includes a secondary conveyor thatfunction as the sole means for initially removing the product containerfrom the immediate vicinity of the injection molding machines (i.e., forfurther processing, packaging and/or conveyance). In the preferredembodiment, the secondary conveyor is a gravity roller conveyor disposedabove the product container conveyor, and a mechanism adapted to raisethe product containers from the product container conveyor to thegravity roller conveyor, upon signal from the control system based uponprocessing parameters, such as part count or weight. In this regard, themicroprocessor may have programming instructions adapted to signal themechanism to move each of the product containers, once supplied, fromthe product container conveyor to the gravity roller conveyor. To sparespace, the gravity roller conveyor is disposed over the productcontainer conveyor and wherein their respective courses are in oppositedirections.

Injection Molding Machine Array with Narrow Inter-Machine Space andOverhead Resin and Coolant Supply

The present invention includes an injection molding factory systemcomprising a building having: (a) a first-level floor supporting aplurality of injection molding machines, each adapted to accept a supplyof resin and each comprising a mold set adapted to be cooled by a liquidcoolant; and (b) a mezzanine level platform above the injection moldingmachines, the mezzanine level platform supporting (1) a resin supply,the resin supply comprising resin conduits adapted to supply resin toeach of the injection molding machines; (2) a supply of liquid coolant,the coolant supply comprising liquid conduits adapted to supply liquidcoolant to each of the mold sets; and (3) a dryer system adapted to drythe resin disposed in fluid contact with the resin supply conduits.

It will be appreciated that the present invention allows for theefficient nesting of injection molding machines so as to conservefactory floor space. In this case, it is preferred that the distancebetween the adjacent injection molding machines is such that only aconveyor resides between the adjacent injection molding machines suchthat there need only be enough space necessary to accommodate theautomatic transport system and any required human operator action. Inmost applications, the distance between the adjacent injection moldingmachines is preferably less than that necessary to accommodate a forklift or other transport device used for handling bulk resin; i.e.,typically wherein the distance between the adjacent injection moldingmachines is less than about 12 feet. In other embodiments, the distancebetween the adjacent injection molding machines need only be thatnecessary to accommodate an automatic product transport system such asthat described herein.

Accordingly, the system of the present invention may be characterized asone that does not require the use of floor-level wheeled transport forthe supply of resin to, or the removal of molded product from, thevicinity of the injection molding machines. It also does not require theuse of floor-level wheeled transport for the supply of mold sets to, orthe removal of mold sets from, the vicinity of the injection moldingmachines.

It is preferred that the injection molding factory system additionallycomprises a vacuum conduit system adapted to convey the resin from theresin supply to the injection molding machines, and preferably whereinthe resin is delivered to the injection molding machines exclusively bythe vacuum conduit system.

The injection molding machines typically eject injected molded articlesthrough mechanisms and systems known and used in the art. In thepreferred embodiment of the present invention, the system additionallycomprises, adjacent to each injection molding machine, a productcontainer conveyor adapted to convey containers so as to be supplied insequence by the injection molded articles, and once supplied, to bemoved away from the respective injection molding machine. Mostpreferably, the injected molded articles are conveyed from eachrespective injection molding machine exclusively by the respectiveproduct container conveyor.

It is also preferred that the building additionally comprises a productpackaging area, and wherein the system additionally comprises a commonconveyor adapted to move the containers from the product containerconveyors to the packaging area.

In a further preferred embodiment the injection molding factory systemadditionally comprises, adjacent to each injection molding machine, apart transporter and a control system with a microprocessor havingprogramming instructions adapted to signal the part transporter tosupply each of the product containers in sequence, and once supplied, tobe moved from the product container conveyor. The control programminginstructions are adapted to signal the part transporter to supply eachof the product containers in sequence, and once supplied, to be movedfrom the product container conveyor.

In a preferred embodiment of the product container conveyor, there is asecondary conveyor as described herein comprising a gravity rollerconveyor disposed above the product container conveyor with a mechanismadapted to raise the product containers from the product containerconveyor to the gravity roller conveyor, upon signal from the controlsystem.

The injection molding factory system also preferably additionallycomprises an overhead crane installed in the building and positioned soas to be able to install a mold set into each of the plurality ofinjection molding machines. This further simplifies the mold set repairor replacement process, and obviates the need for floor level transportand lift mechanisms whose operation increases the need for space, alsoincreases complication in the operation of the system as well as theattendant risk to operators.

The injection molding factory system may also optionally incorporate aremote control system, such as that comprising a microprocessor systemincluding computer programming instructions adapted to monitor orcontrol the operation of the injection molding machines, themicroprocessor system in telecommunication contact with a control panelremote from the building, such that the operation of the plurality ofinjection molding machines may be monitored or controlled from outsidethe building.

The injection molding factory system may also be so completely remotelyoperated that, by use of the remote control system, the injectionmolding factory system may be operated in the absence ofhuman-operational illumination (i.e., at light levels below thatrequired to facilitate human operation of the injection molding machinesand associated resin and product transportation, testing and packagingand handling.

The system may also incorporate in the building a video camera systemdirected at the plurality of injection molding machines, the videocamera in telecommunication contact with a video monitor remote from thebuilding so as to allow the plurality of injection molding machines tobe monitored remotely. This may be used in low-light or even no-lightapplications. The remote control system may also take advantage ofmotion detectors to monitor the movement of persons and materiel withinthe building or its constituent spaces.

In addition, the injection molding factory system may also include ineach of the plurality of injection molding machines, a cavity pressuresensor system associated with the respective mold sets, adapted tomonitor the performance of each respective injection molding machine.Each cavity pressure sensor system in telecommunication contact with acontrol panel remote from the building, such that the performance of theplurality of injection molding machines may be monitored or controlledfrom outside the building.

Injection Molding Machine Array with Narrow Inter-Machine Space andOverhead Resin and Coolant Supply, with Product Container Conveyor

In a preferred embodiment of the present invention, the injectionmolding factory system comprises a building having: (a) a first-levelfloor supporting a plurality of injection molding machines, each adaptedto accept a supply of resin and each comprising a mold set adapted to becooled by a liquid coolant; and (b) a mezzanine level platform above theinjection molding machines, the mezzanine level platform supporting (1)a resin supply, the resin supply comprising resin conduits adapted tosupply resin to each of the injection molding machines; (2) a supply ofliquid coolant, the coolant supply comprising liquid conduits adapted tosupply liquid coolant to each of the mold sets; and (3) a dryer systemdisposed in fluid contact with the resin supply conduits, and adapted todry the resin; wherein the injection molding machines eject injectedmolded articles, and adjacent to each injection molding machine, aproduct container conveyor adapted to convey containers so as to besupplied in sequence by the injection molded articles, and oncesupplied, to be moved away from the respective injection moldingmachine.

This embodiment of the present invention may likewise include the otheraspects of the system as described above.

Method of Injection Molding Using Injection Molding Machine Array withOverhead Resin and Coolant Supply and Automatic Product Supply andContainer Conveyance

The present invention includes an injection molding method comprising:(a) providing a plurality of operating injection molding machines on afirst level, each machine comprising a mold set adapted to accept asupply of resin and adapted to be cooled by a liquid coolant; and (b)supplying, from a level above the injection molding machines, thefollowing: (1) a resin to each mold set; and (2) a liquid coolant toeach mold set; so as to produce injection molded articles; and (c)automatically supplying product containers with the injection moldedarticles; and (d) automatically conveying the product containers fromthe injection molding machines.

The method may additionally comprise automatically supplying the productcontainers with a predetermined number of the injection molded articles,and upon the number being reached, advancing each product container tothe common conveyor.

The method preferably includes periodically, from a level above theinjection molding machines, replacing the mold sets.

In the preferred embodiment, the injection molding factory methodadditionally comprises providing a product packaging area, and whereinthe method additionally comprises conveying the product containers fromthe injection molding machines to the packaging area.

The injection molding factory method may be carried out in the absenceof human-operational illumination, and the operation of the plurality ofinjection molding machines may be monitored or controlled from outsidethe building. Such control may include monitoring or controlling of theautomatic supply of the injection molded articles to the productcontainers from outside the building and/or monitoring or controlling ofthe automatic conveyance of the product containers from the injectionmolding machines, from outside the building. The operation of theplurality of injection molding machines may be visually monitored fromoutside the building through use of video cameras and the like.

Likewise, the method may include monitoring the cavity pressure of eachof the plurality of injection molding machines from outside thebuilding, and controlling the operation of the plurality of injectionmolding machines in response to a change in the cavity pressure.

The present invention allows for the relatively safe and efficientoperation of an injection molding plant facility with little or nodependence upon human operators.

The foregoing and other objects, features, and advantages of thisinvention will become more readily apparent from the following detaileddescription of a preferred embodiment which proceeds with reference tothe accompanying drawings, wherein the preferred embodiment of theinvention is shown and described, simply by way of illustration of thebest mode contemplated of carrying out the invention.

As will be realized, the invention is capable of other and differentembodiments, and its several details are capable of modifications invarious obvious respects, all without departing from the invention.Accordingly, the drawings and description are to be regarded asillustrative in nature, and not as restrictive. It will also beappreciated that the detailed description represents the preferredembodiment of the invention, and that individual steps of the process ofthe invention may be practiced independently so as to achieve similarresults.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan for an injection molding factory system inaccordance with one embodiment of the present invention.

FIG. 2 is a perspective view of the factory layout for an injectionmolding factory system in accordance with one embodiment of the presentinvention.

FIG. 3 is an upper perspective view of the factory layout for aninjection molding facility in accordance with one embodiment of thepresent invention.

FIG. 4 is an elevation view of the factory layout for an injectionmolding facility, as would be seen from beneath the mezzanine levelplatform, in accordance with one embodiment of the present invention.

FIG. 5 is an elevation view of an injection molding factory system aswould be seen at ground level from aside one of the series of injectionmolding machines in a linear array, in accordance with one embodiment ofthe present invention.

FIG. 6 is a detailed elevation view of an injection molding factorysystem as would be seen at ground level from aside one of the series ofinjection molding machines in a linear array, and taken from beneath thefree-standing metal platform that provides the mezzanine level, inaccordance with one embodiment of the present invention.

FIG. 7 is a detailed elevation view of an injection molding factorysystem as would be seen at ground level from aside one of the series ofinjection molding machines in a linear array, and taken from thefirst-floor level, in accordance with one embodiment of the presentinvention.

FIG. 8 is a perspective view of the resin hoppers of the resin supplysupported on the mezzanine level of an injection molding factory systemin accordance with one embodiment of the present invention.

FIG. 9 is a perspective view of the dryer system supported on themezzanine level of an injection molding factory system in accordancewith one embodiment of the present invention.

FIG. 10 is a lower perspective view of the mezzanine level taken fromthe first floor level of an injection molding factory system inaccordance with one embodiment of the present invention.

FIG. 11 is an elevation view of the valve system of the injectionmolding machines used in an injection molding factory system inaccordance with one embodiment of the present invention.

FIG. 12 is an elevation view of the water lines originating from thevalve system of the injection molding machines used in an injectionmolding factory system in accordance with one embodiment of the presentinvention.

FIG. 13 is an additional lower perspective view of the mezzanine leveltaken from the first floor level of an injection molding factory systemin accordance with one embodiment of the present invention.

FIG. 14 is a detailed elevation view of one of the product containerconveyors of an injection molding factory system in accordance with oneembodiment of the present invention.

FIG. 15 is a detailed perspective view of common conveyor that ispositioned to accept product containers in an injection molding factorysystem in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In accordance with the foregoing summary, the following provides adetailed description of the preferred embodiment, which is presentlyconsidered to be the best mode thereof.

FIG. 1 is a schematic plan for an injection molding facility inaccordance with one embodiment of the present invention.

FIG. 1 shows the factory layout for an injection molding facility 1, andshows first floor level 2 and a mezzanine level 3. The mezzanine level 3is supplied in this embodiment by a free-standing metal platform 8 (or amezzanine portion of the building that already exists or has beenconstructed for this purpose).

The present invention thus includes an injection molding factory systemcomprising a building 1 having a first-level floor 2 supporting aplurality of injection molding machines, such as the series of injectionmolding machines 4, 5, 6 and 7 in a linear array. Other arrays may beused depending upon the geometry presented by an existing building wherethe system of the present invention is to be located. Each injectionmolding machine is adapted to accept a supply of resin and eachcomprising a mold set adapted to be cooled by a liquid coolant; and amezzanine level platform 8 above and preferably alongside the injectionmolding machines 4-7, the mezzanine level platform supporting (1) aresin supply 9, the resin supply comprising resin conduits 10 adapted tosupply resin to each of the injection molding machines 4-7; (2) a supplyof liquid coolant 11, the coolant supply comprising liquid conduits 12adapted to supply liquid coolant to each of the mold sets in theinjection molding machines 4-7; and (3) a dryer system 13 adapted to drythe resin disposed in fluid contact with the resin supply conduits 10.The system typically uses a vacuum conduit system to convey the resinfrom the resin supply to the injection molding machines, and normallyexclusively by the vacuum conduit system.

It will be understood that the building housing the system may be of anydimensions necessary to accommodate the array of injection moldingmachines for the desired production, and the invention is not limited tothe layout of the building beyond the use of the two-tiered arrangementdescribed herein, or the length, course, number or geometricalarrangement (i.e., linear, circular, angled, etc.) of the conveyors thatmay be used.

The injection molding machines may be of any type as the particularapplication requires, such as those commercially available from Toyo,and each is adapted to accept a supply of resin and each comprising amold set adapted to be cooled by a liquid coolant.

As reflected in FIG. 1, the distance between the adjacent injectionmolding machines is less than that necessary to accommodate a fork liftused for handling bulk resin, or other machines such as hand trucks andlifts that normally must approach the injection molding machines alongthe side in order to support and maintain their operation. Typically,this distance is less than 12 feet, most preferably less than 8 feet.

The injection molding machines normally are adapted to eject injectedmolded articles (or are supplied with material handling devices, such asrobotic arms and the like for this purpose), and the system preferablyadditionally comprises, adjacent to each injection molding machine, aproduct container conveyor, such as product conveyors 14, 15, 16 and 17,adapted to convey containers so as to be supplied in sequence by theinjection molded articles, and once supplied, to be moved away from therespective injection molding machine. Preferably, the injected moldedarticles are conveyed from each respective injection molding machineexclusively by the respective product container conveyor; and these mostpreferably operate automatically, most typically by having, adjacent toeach injection molding machine, a part transporter and a microprocessorhaving programming instructions adapted to signal the part transporterto supply each of the product containers in sequence, and once supplied,to be moved from the respective product container conveyors 14-17.

In the preferred embodiment, the system also includes a gravity rollerconveyor disposed above each product container conveyors 14-17, and amechanism adapted to raise the product containers from the productcontainer conveyor to the gravity roller conveyor.

The system may also incorporate control systems and logic controls, suchas through the use of a microprocessor having programming instructionsadapted to signal a mechanism to move each of the product containers,once supplied, from the product container conveyors 14-17 to itsassociated gravity roller conveyor. For instance, the gravity rollerconveyor is disposed over the product container conveyor and whereintheir respective courses are in opposite directions. This is shown inFIG. 1 with respect to injection molding machine 4. The productcontainer conveyor 14 advances the product containers along direction Auntil provided with a prescribed number of molded articles at whichpoint the product containers are raised and placed onto a gravity rollerconveyor (disposed over the product container conveyor 14 and theproduct containers then roll in direction B onto common conveyor 19.

Additionally, a microprocessor system comprising computer programminginstructions adapted to monitor or control the operation of theinjection molding machines, may be placed in telecommunication contactwith a control panel remote from the building, such that the operationof the plurality of injection molding machines may be monitored orcontrolled from outside the building.

In the preferred embodiment, the injection molding factory systemadditionally includes a product packaging area 18 disposed belowmezzanine level 3, with a common conveyor 19 adapted to move thecontainers from the product container conveyors to the packaging area 18for further processing, testing, packaging and/or transport.

The building may also be monitored using a video camera, such as videocameras 22, directed at the plurality of injection molding machinesand/or conveyors, as well as elsewhere in the facility as desired, withthe video camera(s) in telecommunication contact with a video monitorremote from the building so as to allow the plurality of injectionmolding machines to be monitored remotely.

Still another optional and preferred feature of the present invention isto provide each of the plurality of injection molding machines with acavity pressure sensor system adapted to monitor the performance of eachrespective injection molding machine, each cavity pressure sensor systemin telecommunication contact with a control panel remote from thebuilding, such that the performance of the plurality of injectionmolding machines may be monitored or controlled from outside thebuilding. Such mold sensor systems and associated controls arecommercially available from RJG of Michigan.

The building may also be provided with an overhead crane 31 (see FIG. 5)installed in such a way as to be able to travel along course 20 andpositioned so as to be able to install a mold set into each of theplurality of injection molding machines 4-7.

As will be appreciated from FIG. 1, additional arrays of injectionmolding machines, such as array 21, may be arranged on the first floorlevel 2, such as in additional linear arrays. These may be served byadditional mezzanine levels placed to serve the further arrays in thesame way as described with respect to the first array.

FIG. 2 is a perspective view of the factory layout for an injectionmolding facility 1, and shows first floor level 2 and a mezzanine level3. The mezzanine level 3 is supplied in this embodiment by afree-standing metal platform 8 (or a mezzanine portion of the buildingthat already exists or has been constructed for this purpose).

FIG. 2 shows an injection molding factory system comprising a building 1having a first-level floor 2 supporting the series of injection moldingmachines 4, 5, 6 and 7 in a linear array. Other arrays or series may beused to fill the balance of the available space, such as by repeatingthe construction shown in this view by providing additional machines andmezzanine set-ups to serve them.

FIG. 2 also shows how each injection molding machine is positioned so asto accept a supply of resin from a mezzanine level platform 8, and eachcomprising a mold set adapted to be cooled by a liquid coolant from amezzanine level platform 8 positioned above—and in this case—alongsidethe injection molding machines 4-7. The mezzanine level platform 8supports the resin supply 9, with resin conduits 10 adapted to supplyresin to each of the injection molding machines 4-7.

FIG. 3 is a upper perspective view of the factory layout for aninjection molding facility, and shows one of the injection moldingmachines 4 and its associated product dispensing arm 27 and dispensingramp 28 that are adapted to supply injection molded parts from theinjection molding machine 4 to product containers, such as productcontainer 29 as it is moved along conveyor 14 in direction A from, andfrom which it is raised in direction C by elevator mechanism 26 ontogravity roller conveyor 23 along which it proceeds along direction Btoward the common conveyor 19. See FIG. 8.

It will be appreciated from this view that the product containerconveyors 14 of the system may be replaced by any equivalent mechanismadapted to remove the injection molded product from the vicinity of theinjection molding machines for further processing, packaging and/orshipment. The present invention thus allows for the operation of anarray of injection molding machines in a relatively space-saving arrayor series to reduce the amount of floor space required, and while alsoeliminating the need for the provision of course ways to accommodate theuse of transport machines such as forklifts, hand trucks, dollies andthe like. This arrangement is therefore safer in that it reduces theareas where transport machines and human operators may travel, thusprotecting the injection molding machines themselves from possibleimpact by transport machines, and reducing the need for human operatorsto operate around the injection molding machines, such as for the supplyof resin, mold change-out and servicing. This arrangement and methodalso reduces the typical interaction between human operators andtransport machines by eliminating much of their normal function (such asthough the use of resin supply systems comprising resin hoppers andresin conduits, injection molded parts container conveyors and overheadcrane systems).

FIG. 4 is an elevation view of the factory layout for an injectionmolding facility, as would be seen from beneath the mezzanine levelplatform 8 and shows one of the injection molding machines 4 in theinjection molding machine array being served from above by resinconduits 10. This view also shows a stack of product containers 30 thatawait loading onto product container conveyor 14 (not shown; see FIGS. 2and 3). From this view, one can appreciate the position of commonconveyor 19 that is arranged so as to be able to accept productcontainers from the gravity roller conveyor 23 (directly or indirectly),and the product containers then are further conveyed in direction D bycommon conveyor 19 for further processing, testing, packaging and/ortransport, such as, in this embodiment, to the packaging area 18 asshown in FIG. 1.

FIG. 5 shows an elevation view of an injection molding factory system aswould be seen at ground level from one of the series of injectionmolding machines 4 in a linear array. From this view one can see therelative position of the overhead crane 31 installed in such a way as tobe able to travel along course 20 (see FIG. 1) and positioned so as tobe able to install a mold set into each of the plurality of injectionmolding machines 4-7. This view also shows the relative position ofcommon conveyor 19, and the free-standing metal platform 8 that providesthe mezzanine level 3 above first-floor level 2, as shown in FIG. 1.

FIG. 6 shows a detailed elevation view of an injection molding factorysystem as would be seen at ground level from one of the series ofinjection molding machines 4 in a linear array, and taken from beneaththe free-standing metal platform 8 that provides the mezzanine level 3.This view shows the relative position of one of the series of injectionmolding machines 4, the water conduits such as conduit 32 coming fromfree-standing metal platform 8 (the water optionally and preferablybeing supplied form above), and the valve system 21 of the injectionmolding machine 4 that pulses cooling water to the mold to createefficient cycle times.

FIG. 7 shows a detailed elevation view of an injection molding factorysystem as would be seen at ground level from aside one of the series ofinjection molding machines 4 in a linear array, and taken from thefirst-floor level 2. This view shows the relative position of one of theseries of injection molding machines 4 with its associated electroniccontrols. This view also shows the relative position of common conveyor19 and its movement of filled product containers along direction D.

FIG. 8 is a perspective view of the resin hoppers of the resin supply 9supported on the mezzanine level 3. This view shows the resin conduits10 that may conduct the resin either to the injection molding machinesvia the drying units, or directly to the injection molding machinesbelow on the first floor level 2, depending upon whether the type ofresin used requires drying.

FIG. 9 is a perspective view of the dryer system 13 comprising one ormore dryers supported on the mezzanine level 3. This view shows theresin conduits 10 that may conduct the resin from the resin supply 9 tothe drying units of the dryer system 13, and further from the dryersystem 13 to the injection molding machines below on the first floorlevel 2, where the type of resin used requires drying.

FIG. 10 is a lower perspective view of the mezzanine level 3 taken fromthe first floor level 2. This view shows the resin conduits 10 that mayconduct the resin from the resin supply 9 or the drying units of thedryer system 13, to the injection molding machines, such as injectionmolding machine 4 below on the first floor level 2.

FIG. 11 is an elevation view of the valve system 21 of the injectionmolding machine 4 that pulses cooling water to the mold to createefficient cycle times.

FIG. 12 is an elevation view of the water lines 22, originating from thevalve system 21 that serve the mold body of the injection moldingmachine 4 with cooling.

FIG. 13 is an additional lower perspective view of the mezzanine level 3taken from the first floor level 2. This view shows the resin conduits10 that may conduct the resin from the resin supply 9 or the dryingunits of the dryer system 13, to the injection molding machines, such asinjection molding machine 4 below on the first floor level 2.

FIG. 14 is a detailed elevation view of one of the product containerconveyors 14 of the system, as would be seen facing the common or trunkline conveyor 19 that is adapted to move the containers from the productcontainer conveyors to the packaging area 18 for further processing,testing, packaging and/or transport. The product container conveyor 14,conveys the containers (such as container 22) so as to be supplied insequence by the injection molded articles, and once supplied, to bemoved away from the respective injection molding machine, alongdirection line A. Once the product container 22 advances to the end ofthe product container conveyor 14, the product containers are raisedalong direction line C by an elevator mechanism 26 that senses thepresence of the product containers in sequence, and places and releasesthe product containers onto a gravity roller conveyor 23 (disposed overthe product container conveyor 14), and the product containers (such asproduct container 24) then roll in direction B toward or onto commonconveyor 19.

FIG. 15 is a detailed perspective view of common conveyor 19 that ispositioned to accept product containers (such as product container 25)that have been delivered to the common conveyor 19 along direction lineB either by direct conveyance or operator action, and which then arefurther conveyed along direction C for further processing and/orpackaging and transport.

Preferably, the injected molded articles are conveyed from eachrespective injection molding machine exclusively by the respectiveproduct container conveyor; and these most preferably operateautomatically, most typically by having, adjacent to each injectionmolding machine, a part transporter and a microprocessor havingprogramming instructions adapted to signal the part transporter tosupply each of the product containers in sequence, and once supplied, tobe moved from the respective product container conveyors 14-17.

In operation, the present invention also includes providing a pluralityof operating injection molding machines on a first level such that eachmachine has a mold set that accepts a supply of resin and is cooled by aliquid coolant. The injection molding machines are supplied, from ahigher level, with the resin and liquid coolant to each mold set, suchthat injection molded articles are produced. Product containers are thenautomatically supplied with the injection molded articles; andautomatically conveyed from the injection molding machines, such as forpackaging and transport.

The method preferably includes supplying product containers with apredetermined number of the injection molded articles, and upon thenumber being reached, advancing each product container to the commonconveyor.

The plurality of operating injection molding machines comprises aproduct container conveyor adapted to convey containers to a commonconveyor, and wherein the method additionally comprises automaticallysupplying the product containers with a predetermined number of theinjection molded articles, and upon the number being reached, advancingeach product container to the common conveyor.

The method also preferably includes periodically, from a level above theinjection molding machines, replacing the mold sets. This may be done byany functional means, and preferably by an overhead crane that travelsalong course 20.

The preferred method includes providing a product packaging area,additionally comprises automatically conveying the product containersfrom the injection molding machines to the packaging area, such as byany functional automatic means, such as by common conveyor 19.

When desired, and using the conveyance and monitoring features of thepresent invention, the method of molding articles of the presentinvention may be carried out in the absence of human-operationalillumination, such in low light or substantially no light conditions.The method may include using lighting only sufficient for visualmonitoring of some portions of the system, such as the product containerconveyor 14-17, the common conveyor 19, the resin supply 9, the coolantsupply 11 and/or packaging area 18. Using the conveyance and monitoringfeatures of the present invention, the system may be adapted foroperation, and the method of the invention practiced, without, orsubstantially without the constant presence of the use of humanoperators. The system may be operated and the method of the inventionpracticed, with only periodic attention from human operators (such asfor low frequency actions, such as machine maintenance, resin hopperreloading, product testing, packaging and/or transport). This may benecessary as little as hourly or at typical shift or partial shiftintervals, such as little as every 4 or 8 hours.

The method additionally may include contemporaneous monitoring orcontrolling the operation of the plurality of injection molding machinesfrom outside the building. This may include monitoring or controlling ofthe automatic supply of the injection molded articles to the productcontainers from outside the building, monitoring or controlling of theautomatic conveyance of the product containers from the injectionmolding machines, from outside the building, visually monitoring theoperation of the plurality of injection molding machines from outsidethe building, and/or monitoring the cavity pressure of each of theplurality of injection molding machines from outside the building, andcontrolling the operation of the plurality of injection molding machinesin response to a change in the cavity pressure.

It will be appreciated that the logical order of the steps are used forpurposes of illustration only, and that the measurements anddeterminations may be varied where not otherwise inconsistent with thepurpose and result obtained in the practice of the invention.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The foregoingembodiments are therefore to be considered in all respects illustrativerather than limiting on the invention described herein. The scope of theinvention is thus indicated by the appended claims rather than by theforegoing description, and all changes that come within the meaning andrange of equivalency of the claims are intended to be embraced therein.

Method of Injection Molding Using Injection Molding Machine Array withOverhead Resin and Coolant Supply and Automatic Product Supply andContainer Conveyance

What is claimed is:
 1. An injection molding method comprising: (a)providing a plurality of operating injection molding machines on a firstlevel, each machine comprising a mold set adapted to accept a supply ofresin and adapted to be cooled by a liquid coolant; and (b) supplying,from a level above said injection molding machines, the following: a. aresin to each said mold set; and b. a liquid coolant to each said moldset; so as to permit said injection molding machines to produceinjection molded articles; (c) automatically supplying productcontainers with said injection molded articles; and (d) automaticallyconveying said product containers from said injection molding machines.2. An injection molding method according to claim 1, wherein each ofsaid plurality of operating injection molding machines comprises aproduct container conveyor adapted to convey containers to a commonconveyor, and wherein said method additionally comprises automaticallysupplying said product containers with a predetermined number of saidinjection molded articles, and upon said number being reached, advancingeach said product container to said common conveyor.
 3. An injectionmolding method according to claim 1, additionally comprisingperiodically, from a level above said injection molding machines,replacing said mold sets.
 4. An injection molding method according toclaim 1 additionally comprising providing a product packaging area, andwherein said method additionally comprises automatically conveying saidproduct containers from said injection molding machines to saidpackaging area.
 5. An injection molding method according to claim 1wherein said method is carried out in the absence of human-operationalillumination.
 6. An injection molding method according to claim 1,wherein said plurality of injection molding machines are enclosed withina building, and additionally comprising monitoring or controlling theoperation of said plurality of injection molding machines from outsidesaid building.
 7. An injection molding method according to claim 1,wherein said plurality of injection molding machines are enclosed withina building, and additionally comprising monitoring or controlling ofsaid automatic supply of said injection molded articles to said productcontainers from outside said building.
 8. An injection molding methodaccording to claim 1, wherein said plurality of injection moldingmachines are enclosed within a building, and additionally comprisingmonitoring or controlling of said automatic conveyance of said productcontainers from said injection molding machines, from outside saidbuilding.
 9. An injection molding method according to claim 1, whereinsaid plurality of injection molding machines are enclosed within abuilding, and additionally comprising visually monitoring the operationof said plurality of injection molding machines from outside saidbuilding.
 10. An injection molding method according to claim 1, whereinsaid plurality of injection molding machines are enclosed within abuilding, and additionally comprising monitoring the cavity pressure ofeach of said plurality of injection molding machines from outside saidbuilding, and controlling the operation of said plurality of injectionmolding machines in response to a change in said cavity pressure.